Mattress Assembly

ABSTRACT

The present disclosure provides improved mattress assemblies, and related methods of use. More particularly, the present disclosure provides advantageous mattress assemblies having a plurality of foam springs (e.g., interchangeable foam springs having different firmness levels) configured to provide customizable comfort and support to a user. The foam springs can be marked/labeled (e.g., color coded; include a firmness identifier, etc.) based on the firmness level associated with each foam spring. The mattress assemblies include foam springs disposed within a portion of the mattress assembly to provide customizable support and comfort to a user. For example, a plurality of individual foam springs with different individual firmness levels can be disposed or positioned within the mattress assembly in various foam spring patterns (e.g., user-selected patterns), as desired.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional application entitled “MATTRESS ASSEMBLY,” which was filed on Dec. 8, 2015, and assigned Ser. No. 62/264,608, the contents of which are herein incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to mattress assemblies and related methods of use and, more particularly, to mattress assemblies having a plurality of foam springs (e.g., interchangeable foam springs having different firmness levels) configured to provide customizable comfort and support to a user.

BACKGROUND OF THE DISCLOSURE

In general, mattress assemblies are known. See, e.g., U.S. Pat. Nos. 7,120,956; 9,003,584 and 9,066,497, and U.S. Patent Pub. No. 2014/0251219, and WO-2014/152915, the entire contents of each being hereby incorporated by reference in their entireties.

Consumers, manufacturers, and distributors generally have many different opinions of the type of a bed and mattress firmness that may provide for a comfortable resting or sleeping condition. There are many different types of beds/mattresses and firmness levels to choose from when deciding on a bed/mattress to purchase. In an attempt to provide users with comfortable beds, manufacturers may use metal springs, foam layers, solid foam blocks, water, air, or other means to provide various types of firmness to a user. These different types of bedding materials may be used individually or in combination. Beds/mattresses may be available in various firmnesses using a combination of springs, foams and materials. However, even though great effort has been dedicated to making a mattress that provides good support and comfort, some solutions are inadequate. As such, a need exists to develop mattress assemblies that include improved features/structures.

Thus, an interest exists for improved mattress assemblies and related methods of use. These and other inefficiencies and opportunities for improvement are addressed and/or overcome by the assemblies, systems and methods of the present disclosure.

SUMMARY OF THE DISCLOSURE

The present disclosure provides advantageous mattress assemblies, and related methods of use. More particularly, the present disclosure provides advantageous mattress assemblies having a plurality of foam springs (e.g., interchangeable foam springs having different firmness levels) configured to provide customizable comfort and support to a user. The foam springs can be marked/labeled (e.g., color coded; include a firmness identifier, etc.) based on the firmness level associated with each foam spring.

In general, the mattress assemblies of the present disclosure include resilient foam springs or resilient foam barrels disposed within a portion of the mattress assembly to provide customizable support and comfort to a user. For example, a plurality of individual foam springs with different individual firmness levels can be disposed, placed or positioned within the mattress assembly in various foam spring patterns (e.g., user-selected patterns), as desired.

The present disclosure provides for a mattress assembly including a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; a first cavity positioned in a top surface of the first region of the material layer, the first cavity extending from a first point between the first end and the mid-point to a second point between the first end and the mid-point; a first placement of foam springs disposed in the first cavity, the first placement of foam springs including one or more foam springs having a first firmness; wherein the second region of the material layer has a second firmness different from the first firmness.

The present disclosure also provides for a mattress assembly further including a cover member configured to house and enclose the material layer and the first placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.

The present disclosure also provides for a mattress assembly further including a comfort layer positioned on the top surface of the material layer. The present disclosure also provides for a mattress assembly wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and further including a second placement of foam springs disposed in the first cavity, the second placement of foam springs including one or more foam springs having a third firmness; wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier. The present disclosure also provides for a mattress assembly wherein the first firmness identifier is a first color, and the second firmness identifier is a second color.

The present disclosure also provides for a mattress assembly further including a second cavity positioned in a top surface of the second region of the material layer, the second cavity extending from a first point between the second end and the mid-point to a second point between the second end and the mid-point; and a second placement of foam springs disposed in the second cavity, the second placement of foam springs including one or more foam springs having the second firmness.

The present disclosure also provides for a mattress assembly further including a third placement of foam springs disposed in the first cavity, the third placement of foam springs including one or more foam springs having a third firmness, the third firmness different than the first firmness and the second firmness. The present disclosure also provides for a mattress assembly further including a cover member configured to house and enclose the material layer and the first, second and third placement of foam springs, the cover member including a first indicator member that indicates a firmness level of the first region and a second indicator member that indicates a firmness level of the second region.

The present disclosure also provides for a mattress assembly further including a fourth placement of foam springs disposed in the second cavity, the fourth placement of foam springs including one or more foam springs having a fourth firmness, the fourth firmness different than the first firmness, the second firmness and the third firmness.

The present disclosure also provides for a mattress assembly further including a cover member configured to house and enclose the material layer and the first and second placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.

The present disclosure also provides for a mattress assembly wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.

The present disclosure also provides for a mattress assembly including a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; a first cavity positioned in a top surface of the first region of the material layer, the first cavity extending from a first point between the first end and the mid-point to a second point between the first end and the mid-point; a second cavity positioned in a top surface of the second region of the material layer, the second cavity extending from a first point between the second end and the mid-point to a second point between the second end and the mid-point; a first placement of foam springs disposed in the first cavity, the first placement of foam springs including one or more foam springs having a first firmness; a second placement of foam springs disposed in the second cavity, the second placement of foam springs including one or more foam springs having a second firmness different from the first firmness; a comfort layer positioned on the top surface of the material layer; a cover member configured to house and enclose the material layer, the comfort layer and the first and second placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.

The present disclosure also provides for a mattress assembly wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier. The present disclosure also provides for a mattress assembly wherein the first firmness identifier is a first color, and the second firmness identifier is a second color.

The present disclosure also provides for a mattress assembly including a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; the first region of the material layer having a first firmness, and the second region of the material layer having a second firmness different from the first firmness; a cover member configured to house and enclose the material layer, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.

The present disclosure also provides for a method for fabricating a mattress assembly including providing a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; positioning a first cavity in a top surface of the first region of the material layer, the first cavity extending from a first point between the first end and the mid-point to a second point between the first end and the mid-point; and disposing a first placement of foam springs in the first cavity, the first placement of foam springs including one or more foam springs having a first firmness; wherein the second region of the material layer defines a second firmness different from the first firmness.

The present disclosure also provides for a method for fabricating a mattress assembly further including enclosing the material layer and the first placement of foam springs in a cover member, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.

The present disclosure also provides for a method for fabricating a mattress assembly wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and further including disposing a second placement of foam springs in the first cavity, the second placement of foam springs including one or more foam springs having a third firmness; wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.

The present disclosure also provides for a method for fabricating a mattress assembly further including positioning a second cavity in a top surface of the second region of the material layer, the second cavity extending from a first point between the second end and the mid-point to a second point between the second end and the mid-point; and disposing a second placement of foam springs in the second cavity, the second placement of foam springs including one or more foam springs having the second firmness.

The present disclosure also provides for a mattress assembly including a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; a cavity positioned in a top surface of the material layer, the cavity extending from a first point between the first end and the mid-point to a second point between the second end and the mid-point; a first placement of foam springs disposed in the cavity, the first placement of foam springs including one or more foam springs positioned in the first region and having a first firmness; a second placement of foam springs disposed in the cavity, the second placement of foam springs including one or more foam springs positioned in the second region and having a second firmness different from the first firmness.

The present disclosure also provides for a mattress assembly further including a cover member configured to house and enclose the material layer and the first and second placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.

The present disclosure also provides for a mattress assembly wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier. The present disclosure also provides for a mattress assembly wherein the first firmness identifier is a first color, and the second firmness identifier is a second color.

Any combination or permutation of embodiments is envisioned. Additional advantageous features, functions and applications of the disclosed assemblies, systems and methods of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and aspects of embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily depicted to scale.

Exemplary embodiments of the present disclosure are further described with reference to the appended figures. It is to be noted that the various features, steps and combinations of features/steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure. To assist those of ordinary skill in the art in making and using the disclosed assemblies, systems and methods, reference is made to the appended figures, wherein:

FIG. 1 is a partial side perspective view of an exemplary mattress assembly according to the present disclosure (corners of inner layers have been cut-off to show foam springs), prior to assembly;

FIG. 2 is a side exploded view of the mattress assembly of FIG. 1;

FIG. 3 is a bottom view of the cover of the mattress assembly of FIG. 1;

FIG. 4 is a side view of the mattress assembly of FIG. 1;

FIG. 5 is a partial side view of another exemplary mattress assembly according to the present disclosure (cover member not shown);

FIG. 6 is a top view of a material layer of the mattress assembly of FIG. 5;

FIG. 6A is a top view of another exemplary material layer;

FIG. 7 is a partial side view of another exemplary mattress assembly according to the present disclosure (cover member not shown);

FIG. 8 is a top view of a material layer of the mattress assembly of FIG. 7;

FIG. 9 is a partial side view of another exemplary mattress assembly according to the present disclosure (cover member not shown);

FIG. 10 is a top view of a material layer of the mattress assembly of FIG. 9; and

FIGS. 11-12 are top views of other configurations of foam springs for use with the material layer of FIG. 10.

DETAILED DESCRIPTION OF DISCLOSURE

The exemplary embodiments disclosed herein are illustrative of advantageous mattress assemblies, and systems of the present disclosure and methods/techniques thereof. It should be understood, however, that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Therefore, details disclosed herein with reference to exemplary mattress assemblies/fabrication methods and associated processes/techniques of assembly and use are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and use the advantageous mattress assemblies/systems and/or alternative mattress assemblies of the present disclosure.

The present disclosure provides improved mattress assemblies, and related methods of use. More particularly, the present disclosure provides advantageous mattress assemblies having a plurality of foam springs (e.g., interchangeable foam springs having different firmness levels), with the foam springs being configured to provide customizable comfort and support to a user. Exemplary foam springs are marked/labeled (e.g., color coded; include a firmness identifier, etc.) based on the firmness level associated with each foam spring.

The mattress assemblies include resilient foam springs or resilient foam barrels disposed within a portion of the mattress assembly to provide customizable support and comfort to a user. The resilient foam springs disposed within the mattress assembly can be provided with varying degrees of firmness. For example, a plurality of individual foam springs with different individual firmness levels can be disposed, placed or positioned within the mattress assembly in various foam spring patterns (e.g., user-selected patterns), as desired. As such, one region of the mattress assembly may be populated with foam springs that are more or less firm or resilient with respect to other foam springs within the mattress assembly, or with respect to other regions of the mattress assembly (e.g., regions not including foam springs). In certain embodiments, the foam springs are individually and removably replaceable or interchangeable relative to the interior of the mattress assembly.

Foam springs of different firmness levels may be placed within a given region of the mattress assembly. For example, one side (e.g., left side) or end (e.g., head portion) of the mattress assembly may be set to a firm user setting by using foam springs and/or materials layers that are more resilient/firm on the firm side/end, and another side (e.g., right side) or end (e.g., leg/foot portion) of the mattress assembly may be set to a soft user setting by using foam springs and/or materials layers that are less resilient/firm on the soft side (or vice versa). Various regions or areas of the mattress assembly may be similarly adjusted via the interchangeable foam springs and/or material layers with different firmness levels. As noted, the foam springs and/or material layers can be marked/labeled (e.g., color coded; include a firmness identifier, etc.) based on the firmness level associated with each foam spring and/or material layer.

The foam springs may be positioned as desired by a manufacturer, distributor, delivery/set-up personnel, a user or other person. As described and disclosed in U.S. Patent Pub. No. 2014/0251219, user interfaces can be provided to allow a person to select firmness settings/patterns for setting the firmness levels/patterns of the mattress assembly per the user requests. A user may determine which type of zoned or patterned mattress assembly suits their particular needs. Planning systems can be provided to help users determine, via software or some other method, what pattern suits their comfort needs. The different firmness springs may be placed in a number of patterns to achieve a desired degree of comfort or support. A pattern of different firmness foam springs may be based on a predetermined position for the foam springs, such as a map of precise foam spring positions and firmness values.

A method and system disclosed herein can include: (i) providing a first plurality of foam springs having a first firmness and providing a second plurality of foam springs having a second firmness different from the first firmness, the first plurality of foam springs with the first firmness are each a first color and the second plurality of foam springs with the second firmness are each a second color different from the first color; determining the foam spring firmness requirements for a user; and configuring at least some of the first and second plurality of foam springs within a mattress assembly to match the user's firmness requirements.

The foam springs may be reconfigurable to meet the users changing firmness requirements. The user's firmness requirements may be determined by a questionnaire, by an interview, by user input to a software application, or the like.

While certain embodiments refer to foam springs fabricated from latex, it should be understood that, while certain embodiments may involve latex, the present disclosure is not limited to latex. Latex is used to provide an example of one type of suitable material and one skilled in the art would understand that there are other suitable materials.

The plurality of foam springs of the mattress assembly can include a first plurality of foam springs having a first firmness level, a second plurality of foam springs having a second firmness level different from the first firmness level, a third plurality of foam springs having a third firmness level different from the first and second firmness levels, etc., to provide various firmness zones, regions, and/or patterns within the mattress assembly. Each foam spring can be marked/labeled (e.g., color coded; include a firmness identifier, etc.) based on the firmness level associated with each foam spring (e.g., high firmness springs colored green, medium firmness springs colored blue, low firmness springs colored pink; high firmness springs marked/labeled HIGH, medium firmness springs marked/labeled MEDIUM, low firmness springs marked/labeled low, etc.).

Referring now to the drawings, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. Drawing figures are not necessarily to scale and in certain views, parts may have been exaggerated for purposes of clarity.

Referring now to FIGS. 1-4, an exemplary mattress assembly 10 generally includes a cover member 12, a comfort layer 14, a material layer 16, and a plurality of foam springs 18.

Mattress assembly 10 can be utilized in connection with a bed facility or the like, for example, a standard bed, twin bed, full size bed, queen size bed, king size bed, crib bed, adjustable bed, non-adjustable bed, etc. The bed facility utilized in conjunction with mattress assembly 10 can also include a box spring, a support frame, and the like.

An adjustable bed may be a type of bed that is capable of adjusting at least one aspect of the shape of the bed/mattress assembly 10 such as a head section, a foot section, leg section, a torso section, or the like. There may be a control interface that a user may use to adjust the position of at least one aspect of the bed/mattress assembly 10.

Exemplary cover member 12 takes the form of a hollow, rectangular cover member 12, and is configured and dimensioned to house, cover and/or enclose comfort layer 14, material layer 16, and the plurality of foam springs 18. Stated another way, comfort layer 14, material layer 16, and the plurality of foam springs 18 are configured to be positioned within cover member 12 to assemble mattress assembly 10.

As shown in FIG. 3, the bottom side 13 of cover member 12 includes an access device or feature 15 to allow users to open and close the bottom side of cover member 12. As such, the layers 14, 16 and springs 18 can positioned inside or outside of cover member 12, as desired. Exemplary access device 15 takes the form of a zipper or the like, although the present disclosure is not limited thereto. Rather, access device/feature 15 can take a variety of forms (e.g., snaps, buttons, hook and loop fasteners, etc.). In some embodiments and as shown in FIG. 3, zipper 15 is configured to open three sides of cover member 12.

Exemplary cover member 12 takes the form of a soft, knit fabric cover member 12 or the like, although the present disclosure is not limited thereto. In exemplary embodiments, the top surface 11A and ends 11B, 11C of cover member 12 take the form of a darkly colored (e.g., dark gray or black) knit fabric that helps promote deeper sleep for a user. The sides 11D, 11E of cover member 12 can take the form of a fabric cover having a speckled appearance. As discussed further below, cover member 12 can also include one or more indicator members 17 (e.g., indicator tags 17) that indicate the firmness level (e.g., firm or soft) of each region or end of layer 16.

As shown in FIGS. 1-2, exemplary comfort layer 14 takes the form of a rectangular layer 14, and can include an upper layer 20 and a lower layer 22. The bottom surface 21 of upper layer 20 can be adhered or attached (e.g., glued) to the top surface 23 of lower layer 22, although the present disclosure is not limited thereto. In other embodiments, layers 20, 22 are not adhered or attached to one another.

It is noted that mattress assembly 10 can include only upper layer 20 and not lower layer 22, or can include only lower layer 22 and not upper layer 20. In some embodiments, assembly 10 may not include layer 14 (e.g., may not include layers 20, 22).

In exemplary embodiments, upper layer 20 is fabricated from latex foam (e.g., 1.5 inch thick latex foam), although the present disclosure is not limited thereto. Rather, it is noted that upper layer 20 can be fabricated from a variety of materials (e.g., urethane foam, visco-elastic foam, polyurethane foam, etc.), and can take a variety of forms/shapes. In general, upper layer 20 is fabricated from a breathable material configured to allow users to regulate body temperature when utilizing mattress assembly 10.

In certain embodiments, lower layer 22 is fabricated from polyurethane foam (e.g., 1.5 inch thick polyurethane foam), although the present disclosure is not limited thereto. Rather, it is noted that lower layer 22 can be fabricated from a variety of materials (e.g., latex foam, urethane foam, visco-elastic foam, etc.), and can take a variety of forms/shapes. In general, lower layer 22 is fabricated from a breathable material configured to allow users to regulate body temperature when utilizing mattress assembly 10.

Exemplary material layer 16 takes the form of a rectangular layer 16, and is fabricated from polyurethane foam, although the present disclosure is not limited thereto. Rather, it is noted that material layer 16 can be fabricated from a variety of materials (e.g., latex foam, urethane foam, visco-elastic foam, etc.), and can take a variety of forms/shapes.

Material layer 16 extends from a first end 24 to a second end 26, and includes/defines a mid-point 28 between the ends 24, 26 (FIG. 2). As such, material layer 16 includes/defines a first region 30 that extends from the first end 24 to the mid-point 28, and includes/defines a second region 32 that extends from the second end 26 to the mid-point 28.

In exemplary embodiments, material layer 16 can include one or more cavities 34 in the top surface 25 of material layer 16. In general, each cavity 34 is configured and dimensioned to house a plurality of foam springs 18. In other embodiments and as discussed further below in connection with FIG. 6A, material layer 16 may not include one or more cavities 34 (e.g., material layer 16″ of FIG. 6A).

As shown in FIGS. 1-2, exemplary cavity 34 takes the form of a rectangular cavity 34 that is positioned in the first region 30 of material layer 16. As such, cavity 34 extends from a point proximal to the first end 24 to a point proximal to mid-point 28. Cavity 34 also extends from a point proximal to a first side 27 of layer 16, and to a point proximal to a second side 29 of layer 16 to define the rectangular cavity 34.

It is noted that exemplary cavity 34 takes the form of a rectangular cavity, however, the present disclosure is not limited thereto. Rather, cavity 34 can take a variety of forms/shapes (e.g., polygonal, square, circular, hexagonal, etc.). Moreover and as discussed further below, cavity 34 can extend across many different regions or areas of layer 16. Additionally, layer 16 can include one or more cavities 34, each extending across many different regions or areas of layer 16.

In general, the plurality of foam springs 18 are interchangeable foam springs 18 having different firmness levels, with the foam springs 18 being configured to provide customizable comfort and support to a user of the mattress assembly 10. Exemplary foam springs 18 can be marked/labeled (e.g., color coded; include a firmness identifier, etc.) based on the firmness level associated with each foam spring 18. As noted, foam springs 18 are configured and dimensioned to be housed within cavity 34 of layer 16.

In exemplary embodiments, a plurality of individual foam springs 18 with different individual firmness levels can be disposed or positioned within cavity 34 of mattress assembly 10 in various foam spring patterns (e.g., user-selected patterns), as desired. As such, one cavity 34 or end/region of the mattress assembly 10 may be populated with foam springs that are more or less firm or resilient with respect to other foam springs 18 within the mattress assembly 10, or with respect to other regions of the mattress assembly (e.g., regions not including foam springs 18). In certain embodiments, the foam springs 18 are individually and removably replaceable or interchangeable relative to the interior of the mattress assembly 10 (e.g., relative to cavity 34).

In exemplary embodiments and as shown in FIGS. 1-2, the present disclosure provides for a mattress assembly 10 having a first plurality of foam springs 18 defining a first firmness and a second plurality of foam springs 18 defining a second firmness different from the first firmness, the first plurality of foam springs 18 with the first firmness are each a first color or other firmness identifier (e.g., colored blue; marked HIGH or H) and the second plurality of foam springs 18 with the second firmness are each a second color or other firmness identifier (e.g., pink; marked MEDIUM or M) different from the first color or identifier (blue/HIGH).

As such, the foam spring 18 firmness requirements for a user may be determined, and the first and second plurality of foam springs 18 can be configured within mattress assembly 10 to match the user's firmness requirements. The foam springs 18 may be reconfigurable to meet the users changing firmness requirements. U.S. Patent Pub. No. 2014/0251219 describes exemplary steps and methods of determining user firmness requirements and configuration orientations for the foam springs 108 within the mattress assembly 10 (e.g., via user input, via a software application or a questionnaire, etc.).

The foam springs 18 positioned within the cavity 34 of material layer 16 may or may not be disposed within or mounted with respect to webbing, containment facilities, attachment facilities, or other alignment systems, as described and disclosed in U.S. Patent Pub. No. 2014/0251219. The webbing, containment/attachment facilities, and/or alignment systems may or may not be connected or attached to the material layer 16. In some embodiments, the foams springs 18 are attached or mounted to the material layer 16.

The foam springs 18 may be a type of soft foam that may include latex foam, urethane foam, visco-elastic foam, polyurethane foam, or the like. The foam springs 18 may be used for bedding, mattresses, pillows, chairs, couches, or the like. The foam springs 18 may be considered a foam support for the mattress assembly 10 (and the associated bed facility). The foam springs 18 may be made of solid foam material, but may additionally have interior and/or exterior openings or the like. The openings may be useful for manufacturability of the foam spring, provide space for added foam spring movement, contain health related materials, and the like.

The cross sectional shape of each foam spring 18 may include a round shape, a square shape, a hexagon shape, an octagon shape, a star shape, an oval shape, or the like. In general, a plurality of foam springs 18 may be contained within the cavity 34 of mattress assembly 10. The plurality of foam springs 18 may be all the same shape, a combination of shapes, or the like. In some cases, the foam spring 18 shapes may provide for spaces between the foam springs 18 to allow the foam springs 18 to have freedom of motion. For example, the plurality of foam springs 18 may be circle shaped or a combination of circle and oval shaped foam springs 18 to provide spaces between the foam springs 18 to allow motion areas for the foam springs 18. In other cases, it may be desired for the foam spring 18 shapes to be selected where the foam springs 18 are in close contact with each other to allow each of the foam springs 18 to support the adjacent foam springs 18. For example, the foam springs 18 may be square foam springs 18 that contact adjacent foam springs 18 on four sides. This may provide support to the foam springs 18 and the adjacent foam springs 18.

The plurality of foam springs 18 contained within the cavity 34 of mattress assembly 10 may have a plurality of different firmnesses. The foam spring 18 firmness may be defined by an indentation load deflection (ILD) value, indentation force deflection (IFD) value, foam density, or the like. IFD, and in a similar manner ILD, is defined as the amount of force, in pounds, required to indent a fifty square inch, round surface into a foam material a certain percentage of the foam material total thickness. IFD may be specified as the number of pounds at a specific deflection percentage for specific height foam. For example, the IFD for a certain foam may be defined as 25 pounds/50 in² at a 25% deflection on a four inch thick piece. The IFD may be influenced by the thickness of the foam material, the size of the material, and the like. For some types of materials, such as latex foam, the ILD value may correlate with the density of the material used. For others, the ILD may be less dependent, or even independent, of the density of the material used.

The firmness may also be measured or described by the density of the foam, in pounds per cubic foot, kilograms per cubic meter, or some other relevant standard. Although the density may not be a direct measurement of firmness, it may have a direct relationship to firmness. For example, a 110 kg/m³ density spring 18 may be firmer than a 95 kg/m³ spring 18 and the 95 kg/m³ spring 18 may be firmer than an 80 kg/m³ density spring 18.

In exemplary embodiments, a color or marking (e.g., firmness identifier) of each foam spring 18 is visible on one or more surfaces of the foam spring 18 when viewing the foam spring 18 installed into mattress assembly 10, with each color/marking indicating a firmness value of the foam spring 18. The color/marking may be presented in a pattern that provides an indication of a firmness value of the firm spring 18. For example and as described and disclosed in U.S. Patent Pub. No. 2014/0251219, the color assigned to a firmness value may be done in accordance with a sequence, wherein the natural spectral progression of color correlates linearly with numerical firmness values.

Foam springs 18 that have different firmness values may be distinguished in a variety of ways including without limitation markings, shape, size, color, and the like. Color may be used to distinguish different firmness springs 18 by using one or more colors added to the foam or applied onto the foam spring 18 resulting in a colored foam spring 18. The color may be visible on one or more surfaces of the foam spring 18 such as the top, barrel or sides, bottom, and the like. Color may be combined with patterning. In an example of color patterning, longitudinal stripes of a color may indicate a different firmness than circumferential stripes of the same color. Colors may be assigned to firmness values in a sequence so that natural progressions of color may inform relative firmness values. For example, foam springs 18 colored with colors of the light spectrum that indicate increasing frequencies of light may be assigned to increasing firmness values so that a red foam spring 18 may have less firmness than a green or violet foam spring 18. The above are merely examples of the use of color to facilitate distinguishing foam springs 18 of different firmness. Other color uses, combinations, shadings, patterns, and the like may be used and are herein included. In addition to facilitating distinguishing foam springs 18 of different firmness, patterns, trends, and transitions of colors of foam springs 18 that are assembled into a mattress assembly 10 may indicate to a viewer a degree of comfort, softness, support, and the like. Firmness zones may take on nicknames associated with the color of the foam springs 18.

With reference again to FIGS. 1-2 and in some embodiments, cavity 34 positioned in the first region 30 of material layer 16 houses and/or is populated with foam springs 18 (e.g., a plurality of pink and blue colored springs 18) that are less firm or resilient with respect to second region 32 of layer 16 (e.g., region 32 of layer 16 that does not include foam springs 18).

As such, after foam springs 18 are housed in cavity 34, the mattress assembly 10 can be assembled together and housed within cover member 12 (e.g., with layer 14 positioned on top of layer 16, and then layers 14 and 16 positioned/enclosed within cover member 12). It is noted that the top surface 25 of layer 16 may or may not be adhered or attached to the bottom surface 31 of layer 22 during assembly.

After assembly of layers 14, 16 within cover member 12, indicator members 17 can be positioned on cover member 12 to indicate the firmness level (e.g., firm or soft) of each region 30, 32 or end 24, 26 of layer 16. As such, a user can choose which region 30, 32 or end 24, 26 (e.g., firm or soft) of layer 16 to utilize for the user's head and feet, or as the left and right side of the mattress assembly, as desired.

For example, an indicator member 17 can be positioned on cover member 12 proximal to region 30 of layer 16 housed within cover member 12, and such indicator member 17 can be labeled “Soft” to indicate that the firmness level of region 30 or end 24 of layer 16 is less firm or resilient with respect to second region 32 of layer 16 (or vice versa).

Correspondingly, an indicator member 17 can be positioned on cover member 12 proximal to region 32 of layer 16 housed within cover member 12, and such indicator member 17 can be labeled “Firm” to indicate that the firmness level of region 32 or end 26 of layer 16 is more firm or resilient with respect to first region 30 of layer 16 (or vice versa).

In other embodiments, it is noted that the indicator members 17 can be associated with (e.g., attached to) layer 16 (or 14).

FIGS. 5-6 are views of another exemplary mattress assembly 10′ according to the present disclosure. Assembly 10′ may be structurally and functionally similar to the assembly 10 discussed above with reference to FIGS. 1-4, with certain additional features.

Mattress assembly 10 generally includes a comfort layer 14, a material layer 16′, and a plurality of foam springs 18, with the layers 14, 16′ and springs 18 configured to be positioned within cover member 12.

As shown in FIG. 5, exemplary comfort layer 14 includes an upper layer 20 and a lower layer 22. Upper layer 20 can be fabricated from latex foam (e.g., 2 inch thick latex foam; 60 kg/m³ density), and lower layer 22 can be fabricated from polyurethane foam (e.g., 1.0 inch thick polyurethane foam; density 2.3 ILD-20), although the present disclosure is not limited thereto.

As shown in FIG. 5, material layer 16′ of mattress assembly 10′ includes an upper section 36 and a lower section 38. Upper section 36 can be fabricated from polyurethane foam (e.g., 2.75 inch thick polyurethane foam; density 2.0 ILD-28), and lower section 38 can be fabricated from polyurethane foam (e.g., 3.0 inch thick polyurethane foam; density 2.0 ILD-32), although the present disclosure is not limited thereto.

As shown in FIG. 6, layer 16′ (e.g., upper section 36 and/or lower section 38) also includes cavity 34′, the cavity 34′ configured and dimensioned to house springs 18, as similarly discussed above. Sections 36, 38 may or may not be adhered or attached to one another.

After assembly of layers 14, 16′ within cover member 12, indicator members 17 can be positioned on cover member 12 to indicate the firmness level (e.g., firm or soft) of each region 30′, 32′ or end of layer 16′, as similarly discussed above in conjunction with assembly 10.

In other embodiments, it is noted that the indicator members 17 can be associated with (e.g., attached to) layer 16′ (or 14).

FIG. 6A depicts a top view of another exemplary material layer 16″ for a mattress assembly of the present disclosure. As shown in FIG. 6A, material layer 16″ may not include one or more cavities 34. As such, the first region 30″ can have a first firmness, and the second region 32″ can have a second firmness (e.g., different than the first firmness).

In an example embodiment, an indicator member 17 can be positioned on cover member 12 proximal to region 30″ of layer 16″ housed within cover member 12, and such indicator member 17 can be labeled “Soft” to indicate that the firmness level of region 30″ or end 24″ of layer 16″ is less firm or resilient with respect to second region 32″ of layer 16″ (or vice versa).

Correspondingly, an indicator member 17 can be positioned on cover member 12 proximal to region 32″ of layer 16″ housed within cover member 12, and such indicator member 17 can be labeled “Firm” to indicate that the firmness level of region 32″ or end 26″ of layer 16″ is more firm or resilient with respect to first region 30″ of layer 16″ (or vice versa)

It is noted that region 30″ can be utilized as the left or right side of the mattress assembly, or as the head or foot portion. Likewise, region 32″ can be utilized as the left or right side of the mattress assembly, or as the head or foot portion.

In other embodiments, it is noted that the indicator members 17 can be associated with (e.g., attached to) layer 16″ (or 14).

FIGS. 7-8 are views of another exemplary mattress assembly 100 according to the present disclosure. Assembly 100 may be structurally and functionally similar to assembly 10, 10′ discussed above with reference to FIGS. 1-6, with certain additional features.

Mattress assembly 100 generally includes a comfort layer 114, a material layer 116, and a plurality of foam springs 18, with the layers 114, 116 and springs 18 configured to be positioned within cover member 12. Comfort layer 114 can include an upper layer 120 and a lower layer 122, and material layer 116 includes an upper section 136 and a lower section 138.

As shown in FIG. 8, layer 116 (e.g., upper section 136 and/or lower section 138) also includes a first cavity 134 positioned on region 130, and a second cavity 134 positioned on region 132, both first and second cavities 134 configured and dimensioned to house springs 18, as similarly discussed above.

In exemplary embodiment, foam springs 18 of different firmness levels may be placed within regions 130, 132 of the mattress assembly 100.

For example, region 132 of the mattress assembly 100 may be set to a firm user setting by using foam springs 18 that are more resilient/firm on the firm end/region 132 (e.g., green and yellow springs 18 in the second cavity 134), and the other end/region 130 of the mattress assembly 100 may be set to a soft user setting by using foam springs 18 that are less resilient/firm on the soft end/region 130 (e.g., blue and pink springs 18 in the first cavity 134).

Regions 130, 132 or areas of the mattress assembly 100 may be similarly adjusted via the interchangeable foam springs 18 with different firmness levels. As noted, the foam springs 18 can be color coded or otherwise marked/indicated based on the firmness level associated with each foam spring 18.

As shown in FIG. 8, cavity 134 positioned in the first region 130 of material layer 116 houses and/or is populated with foam springs 18 (e.g., a plurality of pink and blue colored springs 18) that are less firm or resilient with respect to the springs 18 of second region 132 of layer 116, the cavity 134 of which houses and/or is populated with foam springs 18 (e.g., a plurality of green and yellow colored springs 18) that are more firm or resilient with respect to the springs 18 of first region 130.

After assembly of layers 114, 116 within cover member 12, indicator members 17 can be positioned on cover member 12 to indicate the firmness level (e.g., firm or soft) of each region 130, 132 or end of layer 116, as similarly discussed above in conjunction with assembly 10.

In other embodiments, it is noted that the indicator members 17 can be associated with (e.g., attached to) layer 116 (or 114).

FIGS. 9-10 are views of another exemplary mattress assembly 200 according to the present disclosure. Assembly 200 may be structurally and functionally similar to assembly 10, 10′, 100 discussed above with reference to FIGS. 1-8, with certain additional features.

Mattress assembly 200 generally includes a comfort layer 214, a material layer 216, and a plurality of foam springs 18, with the layers 214, 216 and springs 18 configured to be positioned within cover member 12. Comfort layer 214 can include an upper layer 220 and a lower layer 222, and material layer 216 includes an upper section 236 and a lower section 238.

As shown in FIG. 10, layer 216 (e.g., upper section 236 and/or lower section 238) also includes a cavity 234 that extends across regions 230 and 232, the cavity 234 configured and dimensioned to house springs 18, as similarly discussed above.

In exemplary embodiments, foam springs 18 of different firmness levels may be placed within different regions 230, 232 of cavity 234.

For example, region 230 of cavity 234 may be set to a firm user setting by primarily using foam springs 18 that are more resilient/firm on the firm end/region 230, and the other end/region 232 of cavity 234 may be set to a soft user setting by using foam springs 18 that are less resilient/firm on the soft end/region 232

Regions 230, 232 may be similarly adjusted via the interchangeable foam springs 18 with different firmness levels.

As shown in FIG. 10, the portion of cavity 234 in region 232 houses foam springs 18 (blue, pink) that are less firm or resilient with respect to the springs 18 of region 230 (green, yellow) that are more firm or resilient with respect to the springs 18 of region 232.

As depicted in FIG. 10, the plurality of foam springs 18 of the mattress assembly 200 can include a first plurality of foam springs 18 having a first firmness level (green), a second plurality of foam springs 18 having a second firmness level (yellow) different from the first firmness level (green), a third plurality of foam springs 18 having a third firmness level (blue) different from the first and second firmness levels (green, yellow), and a fourth plurality of foam springs 18 having a fourth firmness level (pink) different from the first, second and third firmness levels (green, yellow, blue) to provide various firmness regions 230, 232, zones, and/or patterns within the cavity 234 of mattress assembly 200. As such, each foam spring 18 can be color coded or labeled/marked based on the firmness level associated with each foam spring 18 (e.g., very high firmness springs 18 colored green or marked VH, high firmness springs 18 colored yellow or marked H, medium firmness springs 18 colored blue or marked M, low firmness springs 18 colored pink or marked L).

After assembly of layers 214, 216 within cover member 12, indicator members 17 can be positioned on cover member 12 to indicate the firmness level (e.g., firm or soft) of each region 230, 232 or end of layer 216, as similarly discussed above in conjunction with assembly 10.

In other embodiments, it is noted that the indicator members 17 can be associated with (e.g., attached to) layer 216 (or 214).

FIGS. 11-12 are top views of other configurations of foam springs 18 for use with cavity 234 of mattress assembly 200, with each color coded spring 18 correlating to a different firmness level spring 18 (e.g., very high firmness springs 18 colored green, high firmness springs 18 colored yellow, medium firmness springs 18 colored blue, low firmness springs 18 colored pink).

Because of the unique construction of the examples set forth herein, a mattress assembly (e.g., assembly 10, 10′, 100, 200) according to the present disclosure is particularly compatible with an adjustable bed base or power base. A power base can include movable sections such as head and foot sections that move up or down. Typically these sections are coupled to actuators and actuator motors that receive signals from a control box to cause these sections to move.

Further in an example, a mattress assembly (e.g., assembly 10, 10′, 100, 200) according to the present disclosure is adapted to be folded and packed in a box. This provides for ease of shipping and delivery to end users.

Although the systems/methods of the present disclosure have been described with reference to exemplary embodiments thereof, the present disclosure is not limited to such exemplary embodiments/implementations. Rather, the systems/methods of the present disclosure are susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof. The present disclosure expressly encompasses such modifications, enhancements and/or variations of the disclosed embodiments. Since many changes could be made in the above construction and many widely different embodiments of this disclosure could be made without departing from the scope thereof, it is intended that all matter contained in the drawings and specification shall be interpreted as illustrative and not in a limiting sense. Additional modifications, changes, and substitutions are intended in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure. 

1. A mattress assembly comprising: a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; a first cavity positioned in a top surface of the first region of the material layer, the first cavity extending from a first point between the first end and the mid-point to a second point between the first end and the mid-point; a first placement of foam springs disposed in the first cavity, the first placement of foam springs including one or more foam springs having a first firmness; wherein the second region of the material layer has a second firmness different from the first firmness.
 2. The mattress assembly of claim 1 further comprising a cover member configured to house and enclose the material layer and the first placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.
 3. The mattress assembly of claim 1 further comprising a comfort layer positioned on the top surface of the material layer.
 4. The mattress assembly of claim 1, wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and further comprising: a second placement of foam springs disposed in the first cavity, the second placement of foam springs including one or more foam springs having a third firmness; wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.
 5. The mattress assembly of claim 4, wherein the first firmness identifier is a first color, and the second firmness identifier is a second color.
 6. The mattress assembly of claim 1 further comprising: a second cavity positioned in a top surface of the second region of the material layer, the second cavity extending from a first point between the second end and the mid-point to a second point between the second end and the mid-point; and a second placement of foam springs disposed in the second cavity, the second placement of foam springs including one or more foam springs having the second firmness.
 7. The mattress assembly of claim 6 further comprising a third placement of foam springs disposed in the first cavity, the third placement of foam springs including one or more foam springs having a third firmness, the third firmness different than the first firmness and the second firmness.
 8. The mattress assembly of claim 7 further comprising a cover member configured to house and enclose the material layer and the first, second and third placement of foam springs, the cover member including a first indicator member that indicates a firmness level of the first region and a second indicator member that indicates a firmness level of the second region.
 9. The mattress assembly of claim 7 further comprising a fourth placement of foam springs disposed in the second cavity, the fourth placement of foam springs including one or more foam springs having a fourth firmness, the fourth firmness different than the first firmness, the second firmness and the third firmness.
 10. The mattress assembly of claim 6 further comprising a cover member configured to house and enclose the material layer and the first and second placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.
 11. The mattress assembly of claim 6, wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.
 12. A mattress assembly comprising: a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; a first cavity positioned in a top surface of the first region of the material layer, the first cavity extending from a first point between the first end and the mid-point to a second point between the first end and the mid-point; a second cavity positioned in a top surface of the second region of the material layer, the second cavity extending from a first point between the second end and the mid-point to a second point between the second end and the mid-point; a first placement of foam springs disposed in the first cavity, the first placement of foam springs including one or more foam springs having a first firmness; a second placement of foam springs disposed in the second cavity, the second placement of foam springs including one or more foam springs having a second firmness different from the first firmness; a comfort layer positioned on the top surface of the material layer; a cover member configured to house and enclose the material layer, the comfort layer and the first and second placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.
 13. The mattress assembly of claim 12, wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.
 14. The mattress assembly of claim 13, wherein the first firmness identifier is a first color, and the second firmness identifier is a second color.
 15. A mattress assembly comprising: a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; the first region of the material layer having a first firmness, and the second region of the material layer having a second firmness different from the first firmness; a cover member configured to house and enclose the material layer, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.
 16. A method for fabricating a mattress assembly comprising: providing a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; positioning a first cavity in a top surface of the first region of the material layer, the first cavity extending from a first point between the first end and the mid-point to a second point between the first end and the mid-point; and disposing a first placement of foam springs in the first cavity, the first placement of foam springs including one or more foam springs having a first firmness; wherein the second region of the material layer defines a second firmness different from the first firmness.
 17. The method of claim 16 further comprising enclosing the material layer and the first placement of foam springs in a cover member, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.
 18. The method of claim 16, wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and further comprising: disposing a second placement of foam springs in the first cavity, the second placement of foam springs including one or more foam springs having a third firmness; wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.
 19. The method of claim 16 further comprising positioning a second cavity in a top surface of the second region of the material layer, the second cavity extending from a first point between the second end and the mid-point to a second point between the second end and the mid-point; and disposing a second placement of foam springs in the second cavity, the second placement of foam springs including one or more foam springs having the second firmness.
 20. A mattress assembly comprising: a material layer that extends from a first end to a second end, the material layer having a mid-point between the first end and the second end, with the material layer having a first region that extends from the first end to the mid-point and a second region that extends from the second end to the mid-point; a cavity positioned in a top surface of the material layer, the cavity extending from a first point between the first end and the mid-point to a second point between the second end and the mid-point; a first placement of foam springs disposed in the cavity, the first placement of foam springs including one or more foam springs positioned in the first region and having a first firmness; a second placement of foam springs disposed in the cavity, the second placement of foam springs including one or more foam springs positioned in the second region and having a second firmness different from the first firmness.
 21. The mattress assembly of claim 20 further comprising a cover member configured to house and enclose the material layer and the first and second placement of foam springs, the cover member including a first indicator member that indicates the first firmness and a second indicator member that indicates the second firmness.
 22. The mattress assembly of claim 20, wherein the one or more foam springs of the first placement of foam springs each include a first firmness identifier; and wherein the one or more foam springs of the second placement of foam springs each include a second firmness identifier different from the first firmness identifier.
 23. The mattress assembly of claim 22, wherein the first firmness identifier is a first color, and the second firmness identifier is a second color. 